United States Patent [19]

[1 1]
[45]

Crane
[54] NON-DESTRUCIIVE INSPECTION OF
COMPOSITE AND ADHESIVELY BONDED

[56]

STRUCTURES

[75] Inventor: Robert L. Crane, Kettering, Ohio

[73] Assignee:

The United States of America as

represented by the Secretary of the

Air Force, Washington, DC.

[21] Appl. No.: 692,840

4,044,253
Aug. 23, 1977

References Cited
U.s. PATENT DOCUMENTS

3,506,827

4/1910

3,857,033

12/1974

3,899,450

8/1975

Alburger ............................ .. 250/302

Cobb ......... ..

Molina ........................... .. 250/302 X

Primary ExaminerArchie R. Borchelt

Attorney, Agent, or FirmJoseph E. Rusz; Cedric H.
Kuhn

[57]

ABSTRACT

Surface defects in composite and adhesively bonded

structures that penetrate to a metal substrate are de

tected by applying a solution of 8-hydroxyquinoline to

[22] Filed:
[51]

June 4, 1976

Int. Cl.2 ........................................... .. G01N 21/16

a surface of such a structure and viewing the surface

under ultraviolet light. The presence of a flaw or crack

leading from the surface to the metal substrate is indi

cated by a ?uorescent glow.

US. Cl. ............................... .. 250/302; 250/46] R

[58]

Field of Search .............................. .. 250/302, 461

7 Claims, N0 Drawings

4,044,253

SUMMARY OF THE INVENTION

This invention resides in a method for detecting
through-the-thickness ?aws in composites comprising a

NON-DESTRUCIIVE INSPECTION OF
COMPOSITE AND ADHESIVELY BONDED
STRUCTURES

plastic sheet or coating bonded to a metal substrate. As

RIGHTS OF THE GOVERNMENT

The invention described herein may be manufactured

used herein, the term through-the-thickness ?aw

and used by or for the Government of the US. for all

indicates a crack or defect in a composite skin that

extends from the skins surface to the underlying metal

governmental purposes without the payment of any

substrate. The present method comprises the steps of

royalty.

applying a solution of 8-hydroxyquinoline in a solvent

therefor to the plastic sheet or coating and then expos
ing the sheet or coating to ultraviolet radiation. The

FIELD OF THE INVENTION

presence of through-the-thickness flaws in the plastic

This invention relates to a method for detecting flaws
sheet or coating is indicated by a ?uorescent glow.
in nonmetallic coatings or skins bonded to metallic
In carrying out the method of this invention, minute
15
substrates.
surface defects that do not penetrate to the metal sub
BACKGROUND OF THE INVENTION
strate do not ?uoresce under ultraviolet light. How
ever, if ?uorescent penetrants are employed as in the
In industry several non-destructive techniques are
processes described in the literature, ?uorescence is
used to determine if structural members are vfree of

defects. For example, in the building industry, steel

beams are inspected prior to use by ultrasonic and X-ray
techniques to detect the possible presence of cracks.
Structural members employed in the construction of
aircraft are inspected for ?aws both before and after

20

observed for both surface defects and through-the

thickness flaws. Thus, the present method makes it
possible to detect only those more serious defects which

may admit corrosive elements to the composites metal

substrate. It is, of course, very important to detect
25 through-the-thickness defects since the corrosion of an
their incorporation into an aircraft.
.
aircraft structural member could lead to structural fail
Several types of structural members are employed in
ure. While it is not intended to restrict the present in
the construction of aircraft. One type that is often used
vention to any particular theory of operation, it is be
has a laminated structure which can be fabricated from
lieved that the 8-hydroxyquinoline which is not itself a
one or more coatings or layers of a plastic material
?uorescent penetrant, reacts with the metal substrate,
bonded with an adhesive or by a heat sealing procedure
thereby forming a metal chelate. The metal chelate so
to a metal substrate. Another type of structural member
formed is a ?uorescent penetrant which ?uoresces
has a honeycomb structure in which a layer in the form
when viewed under ultraviolet light. The method is
of a metallic honeycomb is sandwiched between two
particularly applicable to aircraft components, e. g.,
layers of plastic sheet material. The edges of the honey
coated panels and honeycomb composites, in which the
comb layer are bonded to the sheets by means of an
metal substrate is formed of aluminum, steel or brass.
adhesive or by heat treatment.

As in the building industry, ultrasonic and X-ray test

As mentioned above, the 8-hydroxyquinoline is ap

methods have been used to test structural members

plied as a solution in a solvent therefor. While any suit

able solvent can be employed, it is usually preferred to

prior to their use in aircraft construction and periodi
cally after operational use to determine if they are struc 40 use water, an alcohol or mixtures thereof. Examples of
alcohols that can be used include methanol, ethanol,
turally sound. However, for several reasons such meth
isopropanol, and the like. The amount of 8-hydrox
ods have not proven to be entirely satisfactory. For
yquinoline contained in the solution can vary within
example, the methods involve the use of expensive and
rather broad limits although it is preferred to utilize at
complicated equipment, requiring the services of skilled
technicians. Simpli?ed test procedures have been sug 45 least about 0.001 weight percent, based upon the weight
of the solvent. As a practical matter, the maximum
gested for detecting minute surface defects that utilize
amount employed does not exceed about 2.0 weight
dye penetrant compositions. Examples of such proce
percent although larger amounts can be used. Thus, the
dures are disclosed in US. Pat. Nos. 3,567,932,
amount of 8-hydroxyquinoline used generally ranges
3,814,695 and 3,896,664. While dye penetrants used in
the prior art processes are effective in detecting surface 50 from about 0.001 to 2.0 weight percent, based upon the
weight of the solvent.
defects, they are incapable in detecting whether a ?aw
The solution of 8-hydroxyquinoline can be applied to
penetrants to a metal substrate. In other words, the dye
the surface of the structural member to be inspected by
penetrants present the same appearance in the case of
any of the well known, conventional procedures. It is
surface ?aws as they do with through-the-thickness
often preferred to spray the solution on the surface, but
cracks. Since cracks penetrating to a metal substrate
it can be applied with a roller or brush. Also, the struc
permit water and other corrosive elements to contact
tural S-hydroxyquinoline. can be dipped in a solution of
the substrate, it would be desirable to have an inspection
the 8After applying the 8-hydroxyquinoline solution, a
method that distinguishes between mere surface defects
period of time sufficient for the solution to penetrate
and through-the-thickness cracks in a structural mem
60 any cracks is allowed to_elapse. Depending upon the
ber.
thickness of the skin or coating bonded to the metal
It is a principal object of this invention, therefore, to

provide a method for detecting ?aws in composite

substrate, the soaking period usually ranges from about

structures comprising a metal substrate having a plastic

10 seconds to 30 minutes. If desired, at the end of this

period, excess solution can be removed from the surface

skin or sheet bonded thereto that penetrate the skin or

sheet to the substrate. Other objects and advantages of 65 merely by washing with water or an alcohol. Also,
the invention will become apparent to those skilled in
the art upon consideration of the accompanying disclo

subsequent to the removal of excess solution, it is within

the scope of the invention to air dry the surface for a

sure.

period of time suf?cient to dry the surface but insuf?

4,044,253

cient to dry solution in any through-the-thickness

cracks that may be present. The surface is then exposed
to ultraviolet light and any through-the-thickness ?aw
is indicated by a ?uorescent glow outlining the defect.

thickness ?aws in composite structures. Since processes

using standard ?uorescent penetrants do not distinguish

between minor surface defects and through-the-thick
ness ?aws, it is currently necessary to use radiography

Prior to exposure to the ultraviolet radiation, the sur

face can be coated with a dry developer. Developers
are well known in the art and function to draw or blot

techniques when inspecting for such flaws. By utilizing

residual traces of any metal chelate, which may be

formed, out of any through-the-thickness defects in the

equipment requiring highly trained personnel since

structural member. As a result, any such defects are

rendered more visible when viewed under ultraviolet

dard ?uorescent penetrants can be utilized in practicing

the method of this invention.
As will be evident to those skilled in the art, modifica
tions of the present invention can be made in view of the

the present method, inspection costs are materially de

creased. Thus, it is unnecessary to employ expensive

existing equipment and techniques employed with stan

light.
A more comprehensive understanding of the inven
tion can be obtained by referring to the following illus
trative example which is not intended, however, to be
unduly limitative of the invention.

foregoing disclosure without departing from the spirit

and scope of the invention.
I claim:

1. A method for detecting through-the-thickness

EXAMPLE

?aws in composites comprising a plastic sheet or coat

ing bonded to a metal substrate which comprises the

A portion of an F-4 aircraft rudder in the form of an

aluminum honeycomb core having a boron-epoxy skin
was inspected for defects in the skin that penetrated to
the core. Initially, the rudder was placed horizontally

steps of applying to the sheet or coating a solution of

8-hydroxyquinoline in a solvent therefor; and exposing

the sheet or coating to ultraviolet radiation.

on a table and the area to be inspected was wiped with

'

2. The method according to claim 1 in which the

solvent is selected from the group consisting of water,
an alcohol, and mixtures thereof.
3. The method according to claim 2 in which the
solvent is an alcohol selected from the group consisting

paper towels soaked with a standard penetrant cleaner

(Magna?ux ZC-7). The rudder was then examined

under a Magna?ux ZB-26MF black light in a darkened
room for any evidence of residual ?uorescence. None
was observed. A ?ne spray of a solution of 0.01 weight

of methanol, ethanol and isopropanol.

percent S-hydroxyquinoline in isopropanol was applied

4. The method according to claim 1 in which the

amount of 8-hydroxyquinoline ranges from about 0.001
to 2.0 weight percent, based upon the weight of the
solvent.
5. The method according to claim 4 in which a period
of time ranging from about 10 seconds to 30 minutes is

to the surface of the rudder with an aspirator. After

about 5 minutes, the rudder was again examined under

ZB-26MF black light for evidence of ?uorescence. A

?uorescent halo was observed around a small hole in an

area of the structure that contained a repair patch. The

?uorescent halo indicated that the small hole penetrated

to the aluminum honeycomb. (Subsequent destructive
examination of the rudder con?rmed this indication.) A
standard penetrant developer (Magna?ux ZP-9) was
then applied to the rudder by spraying near the ?uores~
cent indication. The intensity of the ?uorescent halo
was thereby enhanced so that it could be readily photo

allowed to elapse after applying the solution and prior

to exposing the sheet or coating to ultraviolet radiation.
6. The method according to claim 5 in which the

sheet or coating is covered with acoating of dry devel

oper after applying the solution to the sheet or coating.
7. The method according to claim 6 in which the
composite comprises an aluminum honeycomb core
having a plastic sheet bonded thereto.

graphed.
As seen from the foregoing example, the method of
this invention makes it possible to detect through-the

45

50

55

60

65

III

III

UNITED STATES PATENT AND TRADEMARK OFFICE

CERTIFICATE OF CORRECTION
PATENT NO.

DATED

1 August 23, 1977

|NVENTOR(5) 3

4,044,253

Robert L. Crane

It is certified that error appears in the above-identified patent and that said Letters Patent
are hereby corrected as shown below:
Column 2, line 57 "8-hydroxyquinoline" should read member ;
line 58, "8" should read - 8-hydroxyquinoline. -.
Column 3,
line 36, after "honeycomb", insert core .
Column 4, in line
1 of claim 4, change "1" to -- 2 -.

Signed and Scaled this

Tweary-?rst ,D a)! of February I978
[SEAL]

A nest:

RUTH C. MASON
Arresting Officer

LUTRELLE F. PARKER
Acting Commissioner of Patents and Trademarks